Automatic terminal applicator for insulated non-metallic ignition type wires

ABSTRACT

A terminal applicator for attaching an electric terminal to the end of an insulated non-metallic ignition type wire having one or both ends of the wire insulation stripped to expose a short section of the non-metallic conductor. The wire is conveyed in a step by step manner to the terminal applicator. The applicator includes a die set having a movable die and a fixed die. The movable die includes a pusher plate which is moved downwardly with the movable die to partially bend the exposed conductor at the end of the wire downward into the path of motion of the movable die. The whole terminal applicator is moved toward the wire to seat the end of the wire in the terminal ears of an electric terminal. The motion of the applicator is used to bend the downwardly bent conductor back against the outside surface of the insulation so that on crimping of the terminal ears around the insulation, the exposed end of the conductor of the wire will be in electrical contact with the terminal.

United States Patent Randar 51 June 13, 1972 Magnus Randal, MenomoneeFalls, Wis.

[72] Inventor:

[73] Assignee: Artos Engineering Company, New Berlin,

Wis.

[22] Filed: Dec. 24, 1970 211 App]. No.: 101,206

[56] References Cited UNITED STATES PATENTS 2,748,452 6/1956 Pierce..29/63O A 3,231,961 2/1966 Andren et 3,402,452 9/1968 Mraz ..29/203 DTPrimary Examiner-Thomas H. Eager Attorney-James E. Nilles ABSTRACT Aterminal applicator for attaching an electric terminal to the end of aninsulated non-metallic ignition type wire having one or both ends of thewire insulation stripped to expose a short section of the non-metallicconductor. The wire is conveyed in a step by step manner to the terminalapplicator. The applicator includes a die set having a movable die and afixed die. The movable die includes a pusher plate which is moveddownwardly with the movable die to partially bend the exposed conductorat the end of the wire downward into the path of motion of the movabledie. The whole terminal applicator is moved toward the wire to seat theend of the wire in the terminal ears of an electric terminal. The motionof the applicator is used to bend the downwardly bent conductor backagainst the outside surface of the insulation so that on crimping of theterminal ears around the insulation, the exposed end of the conductor ofthe wire will be in electrical contact with the terminal.

13 Claims, 1 1 Drawing Figures PATENTEDJUM 13 1972 SHEET U 0F 4BACKGRGUND OF THE INVENTION I Automatic application of electricterminals to the exposed conductor of an insulated wire has previouslybeen done by a stationary die unit as shown in US. Pat. No. 3,274,664entitled Terminal Attachment Device" and U.S. Pat. No. 3,23l,96lentitled Wire Cutting and Terminal Attaching Machine." In someinstances, it is desirable to bend the exposed copper conductor backagainst theinsulation to obtain electrical contact between the exposedconductor and the terminal. Automatic attachment of electric terminalsdirectly to insulated non-metallic conductor wires has not been done dueto the difficulty in holding the conductor in the bent back position.The conductor has a tendency to return to its straight position makingit difficult to hold the conductor against the insulation while theterminal is being attached to the wire.

In the past, whenever terminals were attached to ignition wire byautomatic machines, two methods were used. The most common methodemployed an intermediate step of inserting a formed metallic wire intothe center of the conductor. The metallic wire was bent around theoutside of the wire in the form of a U before attaching the terminalover the ignition wire and the metallic wire. 7

The second method employed a sharp barb in the terminal which wouldpierce the insulation and make contact with the conductor. The firstmethod involved additional cost and was unreliable. The second methodmade poor electrical contact and was very unreliable.

Whenever electric terminals have been applied to nonmetallic ignitiontype wires using the bent conductor method, the conductor has been bentby hand and held against the insulation whilethe electric terminal isattached to the wire. This is a costly and time consuming process.

SUMMARY OF THE INVENTION The terminal applicator of the-presentinvention makes it possible to automatically attach electric terminalsto-insulated non-metallic ignition type wires, without the intermediatestep of inserting a metallic wire into the conductor portion of the wirebefore attaching the terminal. This is accomplished by initiallystripping the insulation from the end of the wire to expose theconductonThe wire is then held in a fixed position and the applicator ismoved toward the wire. Areciprocally movable pusher plate is provided onthe movable die in the terminal applicator and is moved downward intoengagement with the exposed, portion of the conductor so that the bentconductor lies in the path of motion of the movable die. The motion ofthe applicator toward the insulated wire will bend the downwardly bentend of the conductor back against the insulation as the wire is seatedin the electric terminal. The cars on the electric terminal are thencrimped to the wire with the bent end of the exposed conductor squeezedbetween the insulation and the. electric terminal. An intimate electricconnection is then completed between the conductor and the terminal.

Other objects and advantages will be apparent from the followingdescription of the invention when read in connection with theaccompanying drawings:

THE DRAWINGS FIG. 1 is a perspective view of a portion of a terminalapplicator press with the movable terminal applicator of this inventionshown positioned next to a wire conveyor.

FIG. 2 is a front view in elevation of the applicator.

FIG. 3 is a side view in elevation with the side of the applicatorbroken away to show the linkage assembly for the die set slide bracket.

FIG. 4 is a view taken on line 4-4 of FIG. 3 showing the drive cam forthe slide bracket linkage assembly.

FIG. 5 is a front view of the wire guide assembly with a portion of thefront plate broken away to show the guide fingers.

FIG. 6 is a side view of the moving die set.

FIG. 7 is a front elevation view of the moving die set with the wireguide finger assembly removed.

FIG. 8 is a section view taken on line 8-8 of FIG. 7 showing the upperdie shoe in the upper position and the position of the exposed conductorprior to bending.

FIG. 9 is a section view similar to FIG. 8 showing the'conductor pusherplate at an intermediate position with the exposed conductor bentdownward. f 7

FIG. 10 is a section view similar to FIG. 8 showing the die set of theapplicator moved to the lefi and the exposed conductor bent under theterminal strip.

FIG. 11 is a section view similar toFIG. 10 showing the electricterminal crimped to the insulation-at the end of the wire with theconductor in intimate contact with the terminal.

DETAILED DESCRIPTION 0? rNvEm'roN The temiinal applicator 10 of thisinvention as seen in FIG. 1 is used to automatically secure an electricterminal'l2 tothe end of an insulated non-metallic ignition type wire14. The non-metallic conductor 22 in this type of wire generallyincludes carbon as the conductive material. Terminal applicators 10 areinstalled in temiinal applicator presses 11 which are generally locatedon each side of a step by step type wire conveyor 16 in a position toengage the ends of the wire I4. It should be noted that the wire 14 isheld in a fixed position by wire carrying fingers 18 (only one pair isshown) provided on each side of the conveyor 16. The wires 14 areinitially cut in a cutting and stripping machine where the insulation 20is stripped from each end of the wire 14, leaving a section of theconductor 22 exposed. The wires 14 are picked up by the conveyor l6 andadvanced in a step by step manner past the front of the terminalapplicators 10. The terminals 12 can be applied simultaneously to bothends of the wire or to each at different positions of the wire 14. l I

An electric terminal 12 is generally secured to' both ends of the wire14. In accordance with the invention, the terminal applicators l0 bendthe exposed conductor 22 of the wire 14 back against the outer surfaceof the insulation '16 to make THE TERMINAL APPLICATOR The terminal pressunit 11 (FIGS. 2 and 3) includes a base plate 24 having side plates 25secured thereto for supporting a power unit 26. The power unit is aconventional unit and includes a motor 28 which is operativelyconnectedthrough a reduction gear 30 to drive a shaft 32 which is mounted forrotary motion in a housing 34 secured to the plates 25. An applicatorslide bracket 36 is mounted for reciprocal motion on the base plate 24and is retained therein by guides 38. The applicator slide bracket 36 isreciprocated on the base 24 by means of a linkage assembly 40 which isactuated by a cam assembly 42 mounted on the shaft 32.

In this regard, the linkage assembly 40 (FIG. 3) includes a bell crank44 pivotally mounted on a fixed pin 46. The bell crank 44 is connectedto the slide bracket 36 by a link 48 and is pivoted about the pin 46 bymeans of a connecting rod 50 connected to the bell crank 44 by pin 52and to a cam lever assembly 54 by a pin 56. The cam lever assembly 54(FIG. 4) includes a bell crank 55 mounted on a pin 57 and having a pairof cam rollers 60 which are positioned to engage the cam assembly 42.The cam assembly 42 includes a primary cam 62 and a conjugate cam 64 toprovide positive mechanical movement of the slide bracket 36 in bothdirections. The contour of the cams 62 and 64 are arranged to move theslide bracket 36 forward in synchronism with the operation of theterminal applicator as more fully described below.

The electric terminals 12 are crimped to the end of the wire 14 by meansof a die set 65 (FIGS. 5, 6 and 7) which is mounted in a frame assembly66 on the front of the slide bracket 36. The die set 65 and frameassembly 66 make up the applicator 10. In this regard, the frameassembly 66 includes a bottom plate 68 and a back plate 69. Two guideblocks 72 electrical contact between'the conductor 22 and the terminalhaving openings 74 are secured to a fixed die shoe 70 which is securedto the bottom plate 68. A ramp 67 is secured to the front of the bottomplate 68. A slide block 78 is mounted for reciprocal movement in jibguides 77 provided on the back plate 69. A moving die shoe 81 havingopening 83 is secured to the slide block 78 for movement with the slideblock 78. A crimping die 79 is secured to the moving die shoe 81 in aposition to operatively engage an anvil 71 which is secured to the fixedshoe 70. Accuracy in alignment of the anvil 71 and crimping die 79 isprovided by means of guide pins 87 positioned in the openings 74 in theguide blocks 72 and openings 83 in the moving shoe 81. The die set 65includes the fixed die shoe 70 and the movable die shoe 8]. The fixeddie shoe 70 onto which is secured the guide blocks 72, includes theanvil 71 having an arcuate terminal support surface 80. The crimping die79 is secured to the moving shoe 81 and includes a curved'crimpingsurface 82 which is used to crimp the ears of the terminal 12 againstthe insulation 16 of the wire 14.

Means are provided for closing the crimping die 79 on the terminal 12 intimed sequence with the movement of the slide bracket 36. In thisregard, a connecting rod 84 is connected to a pin 85 in the movableblock 78 by means of a universal bearing 86 and a crank pin 88 providedon the drive shaft 32 also by means of a universal bearing 90. It shouldbe noted that the continuous motion of shaft 32 is transferred to theslide block 78 by the connecting rod 84. The universal bearings 86 and90 allow the die set to be moved horizontally simultaneously with thevertical movement of the slide block 78.

TERMINAL FEED ASSEMBLY Referring to FIGS. 6 and 8, means are shown forfeeding a terminal strip 13 to the die set 65 in the form of a linkageassembly 91. The terminal strip 13 is fed through a tube or guide 92provided on the fixed shoe 70. The terminal 13 is advanced in a step bystep manner by a pawl 94 which is mounted on the end of a lever 96pivotally mounted on a pivot pin 98 on the back plate 69. A second lever100 is secured to the pivot pin 98 and includes a cam roller .102 whichis positioned to engage a cam'104 provided on the slide block 78. Thepawl 94 is biased into engagement with the terminal strip by a spring106 and moves forward on the downward motion of the slide block 78 topush the terminal strip 13 forward in the guide 92. The pivot pin 98 isbiased to return the pawl 94 to its initial position by a spring whichis not shown in the drawing. This is a conventional terminal feedsystem. The terminal 12 is cut from the terminal strip 13 by the motionof the slide block 78 as more particularly described below.

The terminals 12 are held in position in the anvil 71 by means of ahold-down pin 112 which is positioned in a bore 113 in the shoe 81 andbiased by a spring 114 downwardly toward the terminal 12. A cutter blade116 is secured to the movable die shoe 81 and cooperates with a cut ofiblock 115 and cut off die 115a to cut the terminal 12 from the terminalstrip. The operation and construction of the applicator is generallywell known, the upper die shoe 81 being moved into engagement with thelower die shoe 70 to crimp the terminal 12 onthe insulation and to cutthe terminal 12 from the terminal strip.

CONDUCTOR BENDING APPARATUS Means are provided for'bending the exposedconductor 22 of the wire 14 downwardly into the path of motion of thefixed die shoe 70 in order to bend the exposed conductor 22 of the wire14 against the insulation 20. Referring to FIGS. 6 and 7, such means'isin the form of a pusher plate 118 mounted on the front of the crimpingdie 79. The plate 118 includes a flange 120 which projects across thefront of the die set 65. The bottom edge 122 of the flange 120 ispositioned to engage the exposed conductor 22 of the wire as thecrimping die 79 is moved downward past the ramp 67. When the slidebracket 36 is moved horizontally toward the end of the wire 14, theanvil 71 will engage the downwardly bent conductor 22 pushing theconductor 22 under the insulation 20 of the wire 14. As the terminal 12is moved into alignment with the end of the wire 14 the crimping die 79will be moved downward into operative engagement with the anvil 71,crimping the terminal 12 to the insulation on the wire 14. The sequenceof movements is more completely described in the description of theoperation of the applicator 10.

WIRE GUIDE ASSEMBLY Means are provided on the front of the die set 65for aligning and holding the wire 14 in a fixed position on the ramp 67as the die set 65 is moved toward the end of the wire 14. Such means isin the form of a wire guide assembly 124 which is mounted on brackets125 provided on each side of the back plate 69 and a pair of fingers 126having recesses 127 which are closed on the wire 14 forming a guideopening between the recesses 127. The wire 14 slides through the guideopening as the die set 65 is moved toward the wire -'14. In this regard,the fingers 126 are mounted for pivotal movement on a pin 128 providedin a mounting plate 130 which is secured to the side plates 125. Eachfinger 126 includes a roller 123 mounted on apin 129. An air cylinder132 is secured to the mounting plate 130 and includes a piston rod 133which is connected to move a sliding cam block 134 and includes anelongate opening 138 operatively positioned to engage the rollers 123 onthe fingers 126. When the air cylinder 132 is actuated the cam block 134and plate 136 will move downward. The rollers 123 will be pusheddownward rotating the fingers 126, closing them over the wire 14. Theroller 123 will move inward in the slot 138 on downward movement of thecam block 134 and outward on upward movement of the cam block 134.

OPERATION Referring to FIGS. 8 through 1 1, the sequence of operation isshown for the terminal applicator 10 of this invention. It should benoted that the slide block 78 which carries the movable die shoe 81 ismoved continuously through each cycle of operation. As indicated above,the slide block 78 is connected to the crank pin 88 on the shaft 32 byconnecting rod 84 and completes a cycle of operation in each revolutionof the shaft 32. I

In FIG. 8, the position of die set 65 is shown at the start of a cycleof operation. The wire 14 has been moved by the conveyor 16 to aposition opposite the front of the terrninalapplicator 10 with the wire14 resting on the ramp 67. The exposed conductor 22 is located above theanvil 71 and generallyin line with it. As the slide block 78 is moveddownward to the position shown in FIG.'9, the bottom edge 122 of thepusher plate 118 will engage the conductor 22 bending it downward infront of the'anvil 71. Simultaneously with the movement of the pusherplate 118, the pawl 94 will move the terminal strip onto the anvil 71until the electric terminal 12 on the front end of the strip is seatedin the arcuate slot 80 in the anvil 71. As soon as the electric terminal12 is seated on the anvil 71', the hold down hold the terminal 12 inposition.

The slide bracket 36 will start to move forward to the position shown inFIG. 10 after the flange on the pusher plate 1 18 clears the end of thewire 14. The wire guide fingers 126 on the wire guide assembly areclosed on the wire 14 with the pin 112 will engage and wire positionedin the slot formed by the recesses 127 at the end of the guide fingers126. The movement of the slide bracket 36 to the position shown in FIG.10 will bend the conductor 22 back against the insulation 20 at the endof the wire 14. Since the wire 14 is immediately seated in the electricterminal 12, the conductor 22 will be held against the insulation 20 atthe end of the wire 14. The continued motion of the slide block '78 willmove the crimping die 79 toward the anvil 71 crimping the ears on'theelectric terminal 12 onto the end of the wire 14 as seen in FIG. 1 1.The cutter blade 1 16 will simultaneously cut off the terminal 12 at theend of the terminal strip 13. As the slide block 78 starts to moveupward, the conveyor I2 is actuated to move the wire 14 to the nextposition.

RESUME The terminal applicator of this invention can be used toautomatically attach an electric terminal to the end of an insulatednon-metallic ignition type wire. The apparatus automatically bends theexposed conductor of the wire back against the insulation and will holdthe conductor against the wire. The wire is held in a substantiallyfixed position by a wire guide assembly to assure accuracy in alignmentof the wire with the terminal applicator. The movable temiinalapplicator of this invention is fully automatic thereby reducing thetime and cost in securing electric terminals to insulated non-metallicwires.

I claim:

1. An apparatus for crimping an electric terminal to the end of anon-metallic insulated ignition-type wire having a portion of theinsulation removed to expose the conductor at the end of the wire andbeing conveyed in a step by step manner to an operative position withrespect to the apparatus, said apparatus comprising,

a base,

a terminal applicator mounted on said base for movement toward the endof said wire, said applicator including a die set having a fixed anviland a movable crimping die,

means for closing said crimping die on the end of the wire to crimp anelectric terminal to the end of the wire,

means movable with said crimping die set for bending the exposedconductor at the end of the wire into the path of motion of said fixedanvil whereby said fixed anvil on movement of said terminal applicatortoward the end of the wire will bend the downwardly bent conductor backagainst the insulation at the end of the wire.

2. The apparatus according to claim 1 wherein said die set unit includesa ramp positioned to support the end of the wire.

3. The apparatus according to claim 2 including means for holding theend of the wire on the ramp in alignment with said fixed anvil.

4. The apparatus according to claim 3 wherein said holding meansincludes a plate, a pair of fingers mounted for pivotal movement on saidplate between operative and inoperative positions with respect to thewire, each of said fingers including a recess located in a position toform a guide slot between said fingers for said wire, and means forclosing said fingers on said wire.

5. The apparatus according to claim 2 wherein said means for bendingsaid conductor comprises a plate connected to said movable crimping die,said plate including a flange positioned to engage the exposed conductoron closing of said crimping die.

6. An apparatus for attaching an electric terminal to a nonmetallicignition type wire being conveyed in a step by step manner to anoperative position with respect to said apparatus, a portion of theinsulation being stripped from the end of the wire to expose theconductor, said apparatus comprising,

a base,

a slide bracket mounted on said base for movement between operative andinoperative positions with respect to the end of the wire,

a terminal applicator secured to said slide bracket and including afixed anvil and a movable crimping die positioned to operatively engagethe end of the wire,

means for moving said slide bracket to said operative posi- 5 tion withrespect to said wire,

means for closing said applicator to crimp an electric terminal onto theend of the wire, a ramp secured to said applicator and positioned tosupport the end of the wire, and a pusher plate connected to move withsaid movable crimping die and including a flange positioned to engagethe exposed conductor of the wire to bend said conductor into the pathof motion of said fixed anvil. 7. The apparatus according to claim 6wherein said slide bracket moving means includes a cam assemblycontoured to move the slide bracket to the operative position after thepusher plate has bent the conductor into the path of the anvil.

. The apparatus according to claim 6 including means for holding thewire in a fixed position with respect to said fixed anvil.

9. The apparatus according to claim 8 wherein said holding meansincludes a mounting plate connected to said applicator, a pair offingers mounted for pivotal movement about a common axis on saidmounting plate, said fingers each including a recess positioned to forma guide slot for the wire on closing of said fingers, and means forclosing said fingers on the wire prior to engagement of the exposedconductor by said flange on said pusher plate.

10. A die set for crimping an electric terminal on the end of aninsulated non-metallic ignition type wire, said die set including afixed anvil and a movable crimping die,

a ramp operatively connected to said fixed anvil to support the end ofsaid wire,

a pusher plate operatively connected to said movable crimping die toengage and bend the exposed conductor of said wire on closing said dieset,

and means for moving said die set toward the end of said wire wherebythe motion of said anvil will bend said conductor back against theinsulation on the end of the wire.

1 l. The die set according to claim 10 including means connected to saidmovable crimping die for holding the end of the wire in a fixed positionwith respect to said fixed anvil.

' 12. The method of attaching an electric terminal to an insulatednon-metallic wire, said method including the steps of stripping aportion of the insulation from the end of the wire to expose thenon-metallic conductor,

bending the exposed conductor out of axial alignment with the wire,

pushing an electric terminal onto the end of the wire against theexposed conductor to force the exposed conductor back against theinsulation,

and crimping the terminal against the insulation with the conductorsqueezed between the terminal and the insulation.

13. The method according to claim 12 including the step of holding thewire in a fixed position prior to pushing the terminal onto the wire.

1. An apparatus for crimping an electric terminal to the end of anon-metallic insulated ignition type wire having a portion of theinsulation removed to expose the conductor at the end of the wire andbeing conveyed in a step by step manner to an operative position withrespect to the apparatus, said apparatus comprising, a base, a terminalapplicator mounted on said base for movement toward the end of saidwire, said applicator including a die set having a fixed anvil and amovable crimping die, means for closing said crimping die on the end ofthe wire to crimp an electric terminal to the end of the wire, meansmovable with said crimping die set for bending the exposed conductor atthe end of the wire into the path of motion of said fixed anvil wherebysaid fixed anvil on movement of said terminal applicator toward the endof the wire will bend the downwardly bent conductor back against theinsulation at the end of the wire.
 2. The apparatus according to claim 1wherein said die set unit includes a ramp positioned to support the endof the wire.
 3. The apparatus according to claim 2 including means forholding the end of the wire on the ramp in alignment with said fixedanvil.
 4. The apparatus according to claim 3 wherein said holding meansincludes a plate, a pair of fingers mounted for pivotal movement on saidplate between operative and inoperative positions with respect to thewire, each of said fingers including a recess located in a position toform a guide slot between said fingers for said wire, and means forclOsing said fingers on said wire.
 5. The apparatus according to claim 2wherein said means for bending said conductor comprises a plateconnected to said movable crimping die, said plate including a flangepositioned to engage the exposed conductor on closing of said crimpingdie.
 6. An apparatus for attaching an electric terminal to anon-metallic ignition type wire being conveyed in a step by step mannerto an operative position with respect to said apparatus, a portion ofthe insulation being stripped from the end of the wire to expose theconductor, said apparatus comprising, a base, a slide bracket mounted onsaid base for movement between operative and inoperative positions withrespect to the end of the wire, a terminal applicator secured to saidslide bracket and including a fixed anvil and a movable crimping diepositioned to operatively engage the end of the wire, means for movingsaid slide bracket to said operative position with respect to said wire,means for closing said applicator to crimp an electric terminal onto theend of the wire, a ramp secured to said applicator and positioned tosupport the end of the wire, and a pusher plate connected to move withsaid movable crimping die and including a flange positioned to engagethe exposed conductor of the wire to bend said conductor into the pathof motion of said fixed anvil.
 7. The apparatus according to claim 6wherein said slide bracket moving means includes a cam assemblycontoured to move the slide bracket to the operative position after thepusher plate has bent the conductor into the path of the anvil.
 8. Theapparatus according to claim 6 including means for holding the wire in afixed position with respect to said fixed anvil.
 9. The apparatusaccording to claim 8 wherein said holding means includes a mountingplate connected to said applicator, a pair of fingers mounted forpivotal movement about a common axis on said mounting plate, saidfingers each including a recess positioned to form a guide slot for thewire on closing of said fingers, and means for closing said fingers onthe wire prior to engagement of the exposed conductor by said flange onsaid pusher plate.
 10. A die set for crimping an electric terminal onthe end of an insulated non-metallic ignition type wire, said die setincluding a fixed anvil and a movable crimping die, a ramp operativelyconnected to said fixed anvil to support the end of said wire, a pusherplate operatively connected to said movable crimping die to engage andbend the exposed conductor of said wire on closing said die set, andmeans for moving said die set toward the end of said wire whereby themotion of said anvil will bend said conductor back against theinsulation on the end of the wire.
 11. The die set according to claim 10including means connected to said movable crimping die for holding theend of the wire in a fixed position with respect to said fixed anvil.12. The method of attaching an electric terminal to an insulatednon-metallic wire, said method including the steps of stripping aportion of the insulation from the end of the wire to expose thenon-metallic conductor, bending the exposed conductor out of axialalignment with the wire, pushing an electric terminal onto the end ofthe wire against the exposed conductor to force the exposed conductorback against the insulation, and crimping the terminal against theinsulation with the conductor squeezed between the terminal and theinsulation.
 13. The method according to claim 12 including the step ofholding the wire in a fixed position prior to pushing the terminal ontothe wire.